Filler tray and unitary blank for assembling same

ABSTRACT

A filler tray and a unitary blank for assembling the filler tray are provided. The filler tray generally includes a bottom filler, a back filler, and two side fillers that assemble together to define an opened top enclosure adapted to contain one or more high cost product packages. The products contained in the filler tray are accessible from the open top enclosure. The filler trays may be palletized in standard configuration and may be assembled from the unitary blank cut from a single sheet of corrugated fiberboard.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to trays used for shipping and display of products. More particularly, the present invention relates to a product display filler tray that may be palletized in standard full pallet configurations while providing non-product filler space at the back, bottom and sides of the tray.

2. Description of the Related Art

Shipping boxes are well known in the art and are designed to contain objects for convenient transport. Shipping boxes are used to transport consumer products to retail stores. After arrival at the retail store, individual products are removed from their shipping boxes and placed on store shelves for presentation to retail consumers. The transported products are removed by store personnel by lifting the product out of a cut-opened shipping box. When placed on the shelf, products are typically oriented such that the main label of the product, or secondary package enclosing and containing the product, faces the consumer. Shipping boxes are typically made from a sheet of corrugated kraft material, often referred to as corrugated fiberboard.

Owing in part to the popularity of the so-called “club” stores, it is increasingly desirable to display packaged products in the same box in which they are shipped. Such shipping/display boxes eliminate the need for removing individual products from the shipping box and stacking them on a shelf. Products for sale in club stores are increasing shipped and displayed in trays. Shipping/Display trays, hereinafter simply display trays, are boxes that have a single bottom panel, or an assembled bottom formed from multiple bottom flaps, for placement of the product, but are typically opened at the top and have openings in one or more upright walls of the box to display the product label and to facilitate removal of the product directly by the consumer at the point of purchase. Among the problems with which the packaging engineer must deal in devising suitable open walled display trays, is the need for sufficient strength for stacking must be capable of holding.

A number of improvements were made in the prior art boxes to address these issues. For example, Vesborg, U.S. Pat. No. 4,382,504 is directed to a shipping and display box. Spamer, U.S. Pat. No. 5,039,002 is directed to a case for displaying articles in retail outlets, which is preferably formed of corrugated plastic or fiberboard material. DeMott, U.S. Pat. No. 5,277,360 is directed to a stackable box having a display opening. Locking slots and locking tabs are illustrated. Edgerton et al., U.S. Pat. No. 5,372,299 is directed to a combined product shipping and display box. Carr et al., U.S. Pat. No. 5,718,337 discloses a box for a bag stack.

Product shipping boxes and product display trays are often stacked on pallets for more convenient and efficient transport to retail stores, especially to club stores, which typically turn over more product than traditional retail stores. Often, whole pallets of product in display trays are placed in the aisles of club stores for presentation to consumers.

However, for small-sized, high-cost, low-turnover products even club stores do not wish to purchase entire pallets of full display trays containing a large number of these products. The inventory cost to purchase and stock these full pallets is often prohibitive. In the prior art, so-called “filler trays” were provided to address this problem. Filler trays included empty spacers or “fillers” that took up space in the display tray that would otherwise have been occupied by high-price products had the entire display tray been fully loaded. Thus, a filler tray retained the advantage of full display tray palletizing and aisle-way pallet presentation, without the disadvantage of high product inventory cost of display trays without fillers. Fewer of the small sized, high-cost, low turnover products needed to be inventoried since some of the space on the palletized filler trays was occupied by empty fillers.

In the prior art, fillers for filler trays were supplied as separate boxes placed at the bottom, sides, or back of the display tray before product loading. Products were then place adjacent to the fillers to occupy the remaining space in the filler tray. These fillers were separately made and thus costly and inconvenient to use. Further, different sized fillers were needed to accommodate various product space requirements. There remains a need for a filler tray, assembled from a unitary blank, that is durable, strong, economical, versatile, and convenient for use with small, high-cost products.

SUMMARY OF THE INVENTION

Provided is a durable, strong, economical, and versatile filler tray assembled from a unitary blank formed for a single sheet of corrugated fiberboard, which is sometimes referred to as a unitary blank. The unitary blank may be pre-assembled into a “flat”, well known in the art, that presents a knocked-down, planar configuration for convenient shipping and storage of the filler tray. The filler tray provides an enclosure for storing and displaying products that are accessible through the open top of the filler tray. The filler tray may be palletized in standard configurations.

Various fillers, assembled from the unitary blank, take up space in the filler tray that would otherwise be occupied by product. This is advantageous when high-price products are displayed in the tray, as fewer products need to be inventoried when the products are purchased in full pallets.

More particularly, the filler tray includes a bottom filler, a first side filler foldably connected to the bottom filler, a second side filler foldably connected to the first filler, and a back filler foldably connected to the bottom filler and the first side filler and fixedly connected to the second side filler. The various fillers include foldably connected panels, flaps, and tabs that are folded about connecting horizontal and vertical foldlines for assembly into the filler tray. The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled filler tray in accordance with the principles of the present invention;

FIG. 2 is a plan view of a unitary blank used to assemble the filler tray of FIG. 1;

FIG. 3A is a bottom plan view of the filler tray of FIG. 1;

FIG. 3B is a top plan view of the filler tray of FIG. 1, and;

FIGS. 4A-4H is a series of figures that shows assembly of the filler tray of FIG. 1 from the unitary blank of FIG. 2, pre-assembled into a flat.

Reference will now be made to the drawings wherein like numerals refer to like parts throughout. As used herein, positional terms, such as “bottom”, “left” and the like, and directional terms, such as “upward”, “horizontal”, “outward” and the like, are employed for ease of description in conjunction with the drawings. None of these terms is meant to indicate that the described part or assembly must have a specific orientation except when specifically set forth. For simplicity of presentation, repeated parts in the Figures are not necessarily all labeled, although it is understood that these unlabeled parts are to be considered equivalent to duplicate labeled parts.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an assembled filler tray 100 in accordance with the principles of the present invention. The outside surface of filler tray 100 is shown in FIG. 1. Filler tray 100 is assembled from a unitary blank 200 shown in FIG. 2. The inside surface of unitary blank 200 is shown in FIG. 2. Referring to FIGS. 1 and 2 together, filler tray 100 includes a bottom filler 102, a left, e.g., first side filler 104L foldably connected to bottom filler 102, a right, e.g., second side filler 104R foldably connected to bottom filler 102, and a back filler 106 foldably connected to bottom filler 102 and left side filler 104L and fixed connected to right side filler 104R. In one embodiment, back filler 106 is fixedly connected to right side filler 104 by adhesive bonding.

Bottom filler 102, left side filler 104L, right side filler 104R, and back filler 106 together define an opened top enclosure adapted to contain one or more product packages P. An assembled filler tray 100 generally defines the boundaries of the hollow interior portion of the enclosure in which the product packages P are disposed. Product packages P are removed by a consumer through the opened top filler tray 100. A plurality of filler trays 100 may be placed in one or more standard configurations on a pallet (not shown).

Filler tray 100 and the various fillers described, are assembled from foldably connected panels, flaps, tabs, and other parts of unitary blank 200 shown in FIG. 2. As described more fully below with reference to FIGS. 4A-4H, when the various parts are folded about horizontal and vertical fold lines of unitary blank 200, filler tray 100 is assembled. More particularly, FIG. 2 is a plan view of unitary blank 200 used to assemble filler tray 100. In FIG. 2, dashed lines indicate scoring lines and perforation lines on the surface of unitary blank 200 and solid lines indicate cuts entirely through the corrugated fiberboard sheet from which unitary blank 200 is formed. Scoring lines are indentations formed in the surface of the fiberboard stock. Perforation lines are spaced apart cuts partially through the fiberboard stock. Those of ordinary skill in the art recognize that score and perforation lines facilitate folding of corrugated fiberboard stock or similar sheet materials used in display cartons. FIG. 3A is a bottom plan view of filler tray 100. Referring to FIGS. 1, 2 and 3A together, filler tray 100 includes a bottom assembly 208 (FIGS. 2 and 3A). Filler tray 100 (FIG. 1) further includes perimeter panels. The perimeter panels include a first, i.e., a left outer side panel 210L and a second, i.e., a right outer side panel 210R, an outer back panel 212, and a front panel 214. Each of the perimeter panels is generally configured as a rectangular sheet having a length and width. Left outer side panel 210L is foldably connected to outer back panel 212 along a vertical left outer side panel foldline 224, front panel 214 is foldably connected to left outer side panel 210L along a vertical right front panel foldline 226, and right outer side panel 210R is foldably connected to front panel 214 along a vertical right outer side panel foldline 228. In the embodiment shown, the length of left outer side panel foldline 224, front panel foldline 226, and right outer side panel foldline 228 is the same.

Bottom assembly 208 includes a front bottom flap 208F, a back bottom flap 208B, a left bottom flap 208L, and a right bottom flap 208R. Front bottom flap 208F is foldably connected to front panel 214 along a horizontal front bottom flap foldline 216, back bottom flap 208B is foldably connected to back outer panel 212 along a horizontal back bottom flap foldline 218, left bottom flap 208L is foldably connected to left outer side panel 210L along a horizontal left bottom flap foldline 220, and right bottom flap 208R is foldably connected to right outer side panel 210R along a horizontal right bottom flap fold line 222. The bottom flaps of unitary blank 200 are generally configured as surfaces that taper from their respective foldlines to their opposite ends. As described more fully below with reference to FIGS. 4A-4C the bottom flaps are folded about their respective foldlines to assemble bottom assembly 208. When assembled as described below with reference to FIGS. 4A-4C, the bottom flaps that make up bottom assembly 208 are configured to form a 1-2-3 bottom. In other embodiments, the bottom flaps may be differently configured to form other types of well known bottom assemblies, such as regular slotted container (RSC) bottom assembly, or auto-bottom assembly.

Filler tray 100 (FIG. 1) is pre-assembled into a “flat”, well known to those of ordinary skill in the art, for convenient and efficient shipping. Referring again to FIG. 2, filler tray 100 is pre-assembled into a “flat”, by first laying unitary blank 200 on a planar surface such as a floor or table. Then, left outer side panel 210L is folded upward about left outer side panel foldline 224. Next, front panel 214 is folded horizontally along front panel foldline 226 to be parallel with back outer panel 212 still in contact with the flat surface. Next, a perimeter tab 230 foldably connected to back outer panel 212 along a perimeter tab fold line 232 is folded upward about perimeter tab fold line 232. In the embodiment shown, perimeter tab 230 is configured as a rectangular sheet having a length and a width. In this embodiment, the length of perimeter tab 230 is equal to the width of back outer panel 212, although other embodiments are possible. Next, right outer side panel 210R is folded downward along right outer side panel foldline 228 to contact back outer panel 212. Next, the outside surface of upwardly folded perimeter tab 230 is fixedly connected to the inside surface of right outer side panel 210R. In one embodiment, an adhesive material is applied to the outside surface of perimeter tab 230 is fixedly connected perimeter tab 230 to right outer side panel 210R.

In this manner, the perimeter sidewalls of filler tray 100 are formed and unitary blank is pre-assembled. However, as described above, unitary blank 200, now pre-assembled, may be configured as a flat. Right outer side panel 210R, now projecting upward from the flat surface used for pre-assembly, may be pivoted in one direction about perimeter tab foldline 232 where right outer side panel 210R fixedly couples to perimeter tab 230. At the same time, left outer side panel 210L, now also projecting upward from the flat pre-assembly surface is pivot in the same direction about left outer side panel foldline 224. If the direction of pivot is toward the right edge of FIG. 2, right outer side panel 210R and front panel 214 may be made to overlie left outer side panel 210L and back outer panel 212 to form a flat structure. The bottom flaps and other parts, which are shown in FIG. 2 and described more fully below, that are connected to the various perimeter panels, move with their associated perimeter panels. For example, left bottom flap 208L connected to left outer side panel 210L moves with left outer side panel 210L as it pivots about left outer side panel foldline 224. Thus, the entire pre-assembled unitary blank may be made to form a flat.

After pre-assembled unitary blank 200 is received as a flat, further assembly of unitary blank 200 into filler tray 100 commences. FIG. 3A is a bottom plan view of the filler tray 100 after assembly of bottom assembly 208. FIGS. 4A-4H is a series of figures that shows the further assembly filler tray 100 from unitary blank 200 that was pre-assembled into a flat. FIGS. 4A-4C show assembly of bottom panel 208 shown in FIG. 3A. Referring to FIGS. 1, 3A and 4A-4C, in one embodiment, partially assembled filler tray 100 is placed on a planar assembly surface with back outer panel 212 contacting the assembly surface. Next, partially assembled filler tray 100 is squared-up by pivoting the pre-assembled flat as shown by direction arrow 434. As shown, the direction of pivot is to the left of FIG. 4A, thus reversing the rightward direction of the pivot described above where the perimeter panels of unitary blank 200 were formed into a flat. Thus, the perimeter sidewall of filler tray 100 is restored. Next, back bottom flap 208B is folded upward (FIG. 4A) about back bottom flap foldline 218 as shown by direction arrow 436. Back bottom flap 208B defines a bottom notch 438 opposite back bottom flap foldline 218 and adapted to receive a bottom tab 440 opposite front bottom flap foldline 216 and defined by front bottom flap 208F, in a manner well known in the art. Next, left bottom flap 208L and right bottom flap 208R are folded inward (FIG. 4B) about left bottom flap foldline 220 and right bottom flap foldline 222, respectively, as shown by direction arrows 442 and 444. Finally, bottom assembly 208 is fully assembled (FIG. 4C) when front bottom flap 208F is folded about front bottom flap foldline 216, as shown by direction arrow 446 and bottom tab 440 (FIG. 4A) engages and is received by bottom notch 438 (FIG. 4A). Thus, bottom assembly 208 is fully assembled. (FIG. 3A).

Referring again to FIG. 2, unitary blank 200 further includes a back filler top panel 448 foldably connected to back outer panel 212 along a horizontal back filler top panel foldline 450, an inner back panel 452 foldably connected to back filler top panel 448 along a horizontal inner back panel foldline 454, and an inner back panel bottom flap 456 foldably connected to inner back panel 452 along a horizontal inner back panel bottom flap foldline 458. Back filler top panel 448, inner back panel 452, and inner back panel bottom flap 456 are generally configured as rectangular sheets, with inner back panel bottom flap 456 having rounded corners at the ends of the peripheral edge of back panel bottom flap 456 opposite inner back panel bottom flap foldline 458. Further, a left, e.g., first inner back panel side flap 460L is foldably connected to inner back panel 452 along a vertical inner back panel left side flap foldline 462L and a right, e.g., second inner back panel side flap 460L is foldably connected to inner back panel 452 along a vertical inner back panel right side flap foldline 462R. As described more fully below with reference to FIG. 4E, inner back panel 452, inner back panel left side flap 460L and inner back panel right side flap 4602R are scored with a horizontal score line 459 that bisects these parts to facilitates temporary flexing about score line 459.

After the assembly of bottom assembly 208 as described above, further assembly of unitary blank 200 into filler tray 100. FIG. 3B is a top plan view of the filler tray of FIG. 1. FIGS. 4D and 4E show assembly of back filler 106 shown in FIG. 1. Referring to FIGS. 2, 3B and 4D, and 4E together, partially assembled unitary blank 200, is first oriented such that bottom assembly 208 is place in contact with the planar assembly surface. Next, inner back panel left side flap 460L and inner back panel right side flap 460R are folded back (FIG. 4D) about inner back panel left side flap foldline 462L and inner back panel right side flap foldline 462R, respectively, to contact the outside surface of inner back panel 452 as shown by respective direction arrows 466 and 468. Next, inner back panel bottom flap 456 is folded inwardly along inner back panel bottom flap foldline 458 to orient perpendicularly to inner back panel 452 as indicated by direction arrow 470. Next, inner back panel 452 and both inner back panel left side flap 460L and inner back panel right side flap 460R, which have been folded against inner back panel 452, are temporarily folded in half along scoreline 459 (FIG. 4E), as shown by direction arrow 472 to facility insertion of these parts into the cavity defined by partially assembled unitary blank 200 as shown by direction arrow 474. Inner back panel 452 is folded downward about inner back panel foldline 454 for insertion into the cavity. At the same time, back filler top panel 448 is folded downward about back filler top panel fold line 450 until back filler top panel 448 is horizontal. Further, as described more fully below with reference to FIG. 4H, front panel 214 defines a bottom platform 476 (see also FIG. 2) at a vertical left, e.g., first bottom platform cut line 478L and an opposing vertical right, e.g., second bottom platform cut line 478L. Bottom platform 476 is foldably connected to front panel 214 along a horizontal bottom platform foldline 480.and is temporarily pivoted outward about bottom platform foldline 480 as shown by direction arrow 482 to allow for clearance as inner back panel 452 is folded about inner back panel foldline 454. When fully inserted, inner back panel bottom flap 456 contacts bottom assembly 208 and the front edge of back panel bottom flap 456, opposite inner back panel bottom flap foldline 458, and abuts back outer panel 212 to provide stability to filler tray 200. Thus, back filler 106 (FIG. 1) is assembled and fully formed.

Referring again to FIG. 2, unitary blank 200 further includes a left, e.g., first outer side panel top flap 484L foldably connected to left outer side panel 210L along a horizontal left outer side panel top flap foldline 486L and a right, e.g., second outer side panel top flap 484R foldably connected to right outer side panel 210R along a horizontal right outer side panel top flap foldline 486R. A first, e.g., left inner side panel 488L is foldably connected to left outer side panel top flap 484L along a horizontal left inner side panel foldline 490L and a second, e.g., right inner side panel 488R is foldably connected to right outer side panel top flap 484R along a horizontal right inner side panel foldline 490R. Left and right outer side panel top flaps 484L, and 484R are configured as trapazoids having on slanted edge. A first, e.g., left inner side panel front flap 492L is foldably connected to left inner side panel 488L along a vertical left inner side panel front flap foldline 494L and a second, e.g., right inner side panel front flap 492R is foldably connected to right inner side panel 488R along a vertical right inner side panel front flap foldline 494R. Left inner side panel front flap 492L includes a left side filler tab 496L that is cut from left inner side panel front flap 492 and foldably connected to front panel 214 along a horizontal left side filler tab foldline 498L. Similarly, right inner side panel front flap 492R includes a right filler tab 496R that is cut from right inner side panel front flap 492R and foldably connected to front panel 214 along a horizontal right side filler tab foldline 498R. Finally, unitary blank 200 includes a left inner side panel bottom flap 401L also foldably connected to left inner side panel 488L along a horizontal left inner side panel bottom flap foldline 403L and a right inner side panel bottom flap 401R foldably connected to right inner side panel 488R along a horizontal right inner side panel bottom flap foldline 403R.

After the assembly of back filler 106 as described above, further assembly of unitary blank 200 into filler tray 100 commences. FIGS. 4F and 4G show assembly of left side filler 104L and right side filler 104R (FIG. 1). Referring now to FIGS. 2, 3B, 4f, and 4G together, inner back panel left and right side flaps 460L and 460R are folded outwardly (FIG. 4F) along respective inner back panel left and right side flap foldlines 462L and 462R until the front edges of the back panel side flaps opposite their respective foldlines abut against left and right inner side panel 488L and 488R, respectively as shown by direction arrow 483. The front edges of the back panel side flaps wedge in the corners formed by front panel foldline 226 and right outer side panel foldline 228 to provide cross bracing to filler tray 200. Next, left side filler tab 496L and right side filler tab 496R are folded inwardly until horizontal along respective left and right side filler tab foldline 498L and 498R as shown by direction arrows 499. Referring now to FIGS. 2 and 4G, left and right inner side panel front flaps 492L and 492R are folded inward along left and right inner side panel front flap foldlines 494L and 494R, respectively, as shown by direction arrow 415. Next, left and right inner side panel bottom flaps 401L and 401R are folded inwardly along left and right inner side panel bottom flap foldlines 403L and 403R, respectively, as shown by direction arrow 417. In FIG. 4G, right side filler 104R (FIG. 1) is shown assembled as described above while right side filler 104L (FIG. 1) is shown before assembly. Next, after both left and right side fillers 104L and 104R are assembled as described, left and right side fillers 104L and 104R are folded inward into the cavity of filler tray 100 as shown by direction arrow 419. After assembly, left and right side fillers 104L and 104R are folded about respective left and right outer side panel top flap foldlines 486L and 486R and at the same time about respective left and right inner side panel foldlines 490L and 490R. In this manner, left and right outer side panel top flaps 484L and 484R are positioned horizontally while left and right side fillers 104L and 104R are positioned in the interior cavity of filler tray 100. Thus, left and right side fillers 104L and 104R are assembled.

After the assembly of left and right side fillers 104L and 104R, further assembly of unitary blank 200 into filler tray 100 commences. FIGS. 4H shows assembly of bottom filler 102 (FIG. 1). Referring now to FIGS. 2 and 4H together, bottom platform 476 defines a bottom platform support flap 405 that is foldably connected to bottom platform 476 along a bottom platform support flap fold line 407. Bottom platform support flap 405 is first folded up about bottom platform support flap 405 as shown by direction arrow 421. Next, bottom platform 476 is folded into the cavity of filler tray 100 as shown by direction arrow 423. Finally, a bottom platform tab 413 is inserted into an inner back panel slot 415 cut into inner back panel 452. When bottom filler 102 is assembled, bottom platform support flap 405 vertically supports the back edge of bottom platform 476 and bottom platform tab 413 to inner back panel slot 415 insertion locks bottom platform 476 in place. Thus, assembly of unitary blank 200 into filler tray 100 as shown in FIG. 1 is complete. A filler tray, assembled from a unitary blank that is durable, strong, economical, versatile, and convenient for use with small, high-cost products has been provided.

From this disclosure, one of ordinary skill in the art would recognize that other conventional materials and fabrication techniques could be substituted. Also based on this disclosure, the person of ordinary skill in the art would further recognize that the relative proportions and positions of the parts illustrated could be varied without departing from the spirit and scope of the invention. 

1. A filler tray comprising: a bottom filler a first side filler foldably connected to said bottom filler; a second side filler foldably connected to said bottom filler; and a back filler foldably connected to said bottom filler and said first side filler, and fixedly connected to said second side filler.
 2. The filler tray of Claim 1 wherein said bottom filler, said first side filler; said second side filler, and said back filler together define an open top enclosure adapted to contain one or more product packages.
 3. The filler tray of claim 1 wherein said filler tray comprises corrugated fiberboard.
 4. The filler tray of claim 1 wherein said filler tray is assembled from a single sheet of planar corrugated fiberboard.
 5. The filler tray of claim 1 wherein said back filler is fixed connected to said second side filler by adhesive.
 6. The filler tray of claim 1 further comprising perimeter panels comprising: an outer back panel; a first outer side panel foldably connected to said outer back panel; a front panel foldably connected to said first outer panel; and a second outer side panel foldably connected to said front panel.
 7. The filler tray of claim 1 wherein said bottom filler comprises a bottom assembly foldably connected to a front panel, and; a bottom platform foldably connected to said front panel.
 8. The filler tray of claim 1 wherein said back filler comprises an outer back panel; a back filler top panel foldably connected to said back outer panel; an inner back panel foldably connected to said back filler top panel, and; an inner back panel bottom flap foldably connected to inner back panel.
 9. The filler tray of claim 8 further comprising: a first inner back panel side flap foldably connected to said inner back panel, and; a second inner back panel side flap foldably connected to said inner back panel.
 10. The filler tray of claim 1 wherein said first side filler comprises: an outer side panel; a outer side panel top flap foldably connected to said outer side panel; an inner side panel foldably connected to said outer side panel top flap; a inner side panel bottom flap foldably connected to said inner side panel, and; an inner side panel front flap foldably connected to said inner side panel.
 11. A unitary blank foldable into a filler tray of claim
 1. 12. The unitary blank of claim 11 wherein said unitary blank comprises corrugated fiberboard.
 13. The unitary blank of claim 1 The unitary blank of claim 11 is formed from a single sheet of planar corrugated fiberboard.
 14. The unitary blank of claim 11 wherein said unitary blank is pre-assembled into a flat. 